2004 CHEVROLET MALIBU Owners Manual

Maintenance Footnotes
†The U.S. Environmental Protection Agency or the
California Air Resources Board has determined that the
failure to perform this maintenance item will not nullify
the emission warranty or limit recall liability prior to
the completion of the vehicle’s useful life. We, however,
urge that all recommended maintenance services be
performed at the indicated intervals and the
maintenance be recorded.
(a)Visually inspect brake lines and hoses for proper
hook-up, binding, leaks, cracks, chang, etc. Inspect
disc brake pads for wear and rotors for surface
condition. Inspect other brake parts, including calipers,
parking brake, etc.
(b)Visually inspect front and rear suspension and
steering system for damaged, loose or missing parts or
signs of wear. Inspect power steering lines and
hoses for proper hook-up, binding, leaks, cracks,
chang, etc.(c)Visually inspect hoses and have them replaced if they
are cracked, swollen or deteriorated. Inspect all pipes,
ttings and clamps; replace with genuine GM parts as
needed. To help ensure proper operation, a pressure test
of the cooling system and pressure cap and cleaning the
outside of the radiator and air conditioning condenser is
recommended at least once a year.
(d)Visually inspect wiper blades for wear or cracking.
Replace blade inserts that appear worn or damaged
or that streak or miss areas of the windshield.
(e)Make sure the safety belt reminder light and all your
belts, buckles, latch plates, retractors and anchorages
are working properly. Look for any other loose or
damaged safety belt system parts. If you see anything
that might keep a safety belt system from doing its
job, have it repaired. Have any torn or frayed safety belts
replaced. Also look for any opened or broken air bag
coverings, and have them repaired or replaced. (The air
bag system does not need regular maintenance.)
6-7

(f)Lubricate all key lock cylinders, door hinges and
latches, hood hinges and latches and trunk lid hinges
and latches. More frequent lubrication may be required
when exposed to a corrosive environment. Applying
silicone grease on weatherstrips with a clean cloth will
make them last longer, seal better and not stick or
squeak.
(g)Check system for interference or binding and for
damaged or missing parts. Replace parts as needed.
Replace any components that have high effort or
excessive wear. Do not lubricate accelerator or cruise
control cables.
(h)Change automatic transaxle uid and lter if the
vehicle is mainly driven under one or more of these
conditions:
In heavy city traffic where the outside temperature
regularly reaches 90°F (32°C) or higher.
In hilly or mountainous terrain.
When doing frequent trailer towing.
Uses such as found in taxi, police or delivery
service.If you do not use your vehicle under any of these
conditions, the uid and lter do not require changing.
(i)Drain, ush and rell cooling system. See Engine
Coolant on page 5-24for what to use. Inspect hoses.
Clean radiator, condenser, pressure cap and ller neck.
Pressure test the cooling system and pressure cap.
(j)A uid loss in any vehicle system could indicate a
problem. Have the system inspected and repaired and
the uid level checked. Add uid if needed.
6-8

Owner Checks and Services
These owner checks and services should be performed
at the intervals specied to help ensure the safety,
dependability and emission control performance of your
vehicle. Your GM Goodwrench dealer can assist you
with these checks and services.
Be sure any necessary repairs are completed at once.
Whenever any uids or lubricants are added to your
vehicle, make sure they are the proper ones, as shown
inRecommended Fluids and Lubricants on page 6-12.
At Each Fuel Fill
It is important to perform these underhood checks at
each fuel ll.
Engine Oil Level Check
Check the engine oil level and add the proper oil if
necessary. SeeEngine Oil on page 5-17for further
details.
Notice:It is important to check your oil regularly
and keep it at the proper level. Failure to keep your
engine oil at the proper level can cause damage
to your engine not covered by your warranty.
Engine Coolant Level Check
Check the engine coolant level and add
DEX-COOL®coolant mixture if necessary. SeeEngine
Coolant on page 5-24for further details.
Windshield Washer Fluid Level Check
Check the windshield washer uid level in the windshield
washer tank and add the proper uid if necessary.
At Least Once a Month
Tire Ination Check
Visually inspect your tires and make sure tires are inated
to the correct pressures. Do not forget to check your
spare tire. SeeTires on page 5-50for further details.
Cassette Tape Player Service
Clean cassette tape player. Cleaning should be done
every 50 hours of tape play. SeeAudio System(s)
on page 3-52for further details.
6-9

At Least Once a Year
Starter Switch Check
{CAUTION:
When you are doing this inspection, the
vehicle could move suddenly. If the vehicle
moves, you or others could be injured.
1. Before you start, be sure you have enough room
around the vehicle.
2. Firmly apply both the parking brake and the regular
brake. SeeParking Brake on page 2-29if necessary.
Do not use the accelerator pedal, and be ready to
turn off the engine immediately if it starts.
3. Try to start the engine in each gear. The starter
should work only in PARK (P) or NEUTRAL (N).
If the starter works in any other position, contact
your GM Goodwrench dealer for service.
Automatic Transaxle Shift Lock Control
System Check
{CAUTION:
When you are doing this inspection, the
vehicle could move suddenly. If the vehicle
moves, you or others could be injured.
1. Before you start, be sure you have enough room
around the vehicle. It should be parked on a level
surface.
2. Firmly apply the parking brake. SeeParking Brake
on page 2-29if necessary.
Be ready to apply the regular brake immediately if
the vehicle begins to move.
3. With the engine off, turn the key to the ON position,
but do not start the engine. Without applying the
regular brake, try to move the shift lever out
of PARK (P) with normal effort. If the shift lever
moves out of PARK (P), contact your GM
Goodwrench dealer for service.
6-10

Ignition Transaxle Lock Check
While parked, and with the parking brake set, try to turn
the ignition key to OFF in each shift lever position.
The key should turn to OFF only when the shift lever
is in PARK (P).
The key should come out only in OFF.
Contact your GM Goodwrench dealer if service is
required.
Parking Brake and Automatic Transaxle
Park (P) Mechanism Check
{CAUTION:
When you are doing this check, your vehicle
could begin to move. You or others could be
injured and property could be damaged. Make
sure there is room in front of your vehicle in
case it begins to roll. Be ready to apply the
regular brake at once should the vehicle begin
to move.Park on a fairly steep hill, with the vehicle facing
downhill. Keeping your foot on the regular brake, set the
parking brake.
To check the parking brake’s holding ability: With
the engine running and transaxle in NEUTRAL (N),
slowly remove foot pressure from the regular
brake pedal. Do this until the vehicle is held by the
parking brake only.
To check the PARK (P) mechanism’s holding ability:
With the engine running, shift to PARK (P). Then
release the parking brake followed by the regular
brake.
Contact your GM Goodwrench dealer if service is
required.
Underbody Flushing Service
At least every spring, use plain water to ush any
corrosive materials from the underbody. Take care to
clean thoroughly any areas where mud and other debris
can collect.
6-11

Recommended Fluids and
Lubricants
Fluids and lubricants identied below by name, part
number or specication may be obtained from your
dealer.
Usage Fluid/Lubricant
Engine OilEngine oil which meets GM
Standard GM6094M and displays
the American Petroleum Institute
Certied for Gasoline Engines
starburst symbol. To determine the
proper viscosity for your vehicle’s
engine, seeEngine Oil on
page 5-17.
Engine Coolant50/50 mixture of clean, drinkable
water and use only DEX-COOL
®
Coolant. SeeEngine Coolant on
page 5-24.
Hydraulic Brake
SystemDelco Supreme 11 Brake Fluid or
equivalent DOT-3 brake uid.
Usage Fluid/Lubricant
Windshield
Washer SolventGM Optikleen
®Washer Solvent.
Automatic
TransaxleDEXRON
®-III Automatic
Transmission Fluid.
Key Lock
CylindersMulti-Purpose Lubricant, Superlube
(GM Part No. U.S. 12346241, in
Canada 10953474).
Hood Latch
Assembly,
Secondary
Latch, Pivots,
Spring Anchor
and Release
PawlLubriplate Lubricant Aerosol (GM
Part No. U.S. 12346293, in Canada
992723) or lubricant meeting
requirements of NLGI #2, Category
LB or GC-LB.
Hood and Door
HingesMulti-Purpose Lubricant, Superlube
(GM Part No. U.S. 12346241, in
Canada 109435474).
Weatherstrip
ConditioningDielectric Silicone Grease (GM Part
No. U.S. 12345579, in Canada
992887).
6-12

Normal Maintenance Replacement Parts
Replacement parts identied below by name, part number, or specication can be obtained from your dealer.
Part GM Part Numbers ACDelco®Part
Numbers
Engine Air Cleaner/Filter 24577608 A1615C
Engine Oil Filter
2.2L Engine
3.5L Engine24460713
25010792PF2244G
PF47
Spark Plugs
2.2L Engine
3.5L Engine25337472
1256838741–981
41–101
Windshield Wiper Blades
Passenger’s Side
Driver’s Side19.6 inches (48.0 cm)
22.0 inches (56.0 cm)50.0 cm
55.0 cm
6-13

Engine Drive Belt Routing
6-14